Automated inspection systems using industrial robots have been available for a number
of years, including the IntACom system at TWI Wales. Utilising phased array ultrasonic
probes to inspect complex geometries, the IntACom system is routinely used in inspections
of composite components. The present work introduces methods for improving and
quantifying the accuracy of an automated inspection system. The key challenges are identified
and addressed through calibration procedures and interfacing multiple sensors with
industrial robots for Non Destructive Evaluation (NDE) purposes. A novel method for
improving the Tool Centre Point (TCP) calibration of an industrial robot when the tool
is an ultrasonic phased array probe is also introduced. Experimental trials show that the
average positioning error is less than 0.5mm using this new method.In the present work we introduce a number of methods for improving and quantifying the accuracy of an automated inspection system. The key challenges are identified and addressed through a number of methods including calibration procedures and interfacing multiple sensors with industrial robots for Non Destructive Evaluation (NDE) purposes. The authors also introduce a novel method for improving the Tool Centre Point (TCP) calibration of an industrial robot when the tool is an ultrasonic phased array probe. A comparison and analysis of the impact this method has on the accuracy of NDE scans is also presented.